Rotary Exchanger Aluminium 3-Way Mix RXA3MX

Original Instructions Air Handing Units

Installation, Operations and Maintenance Manual

2019 Release

ECE UK LTD Pharaoh House, Arnolde Close, Rochester, Kent. ME2 4QW

Rotary Exchanger Aluminium 3-Way Mix RXA3MX

IOM

Installation, Operation and Maintenance

for ECE air handling and conditioning units

Table of Contents 1

Table of Contents

Table of Contents ................................................................................................................................................................................................................... 1

Purpose ................................................................................................................................................................................................................................. 3

Checks at Design Stage ........................................................................................................................................................................................................ 4

Air Inlets and Discharges .................................................................................................................................................................................................. 5

Acoustics - Vibration ......................................................................................................................................................................................................... 7

Services - Connections ..................................................................................................................................................................................................... 7

Commissioning & Fault Finding ........................................................................................................................................................................................ 7

Maintenance Repair and Renewal .................................................................................................................................................................................... 8

General ............................................................................................................................................................................................................................. 8

Checks at Order Stage .......................................................................................................................................................................................................... 9

General Information ........................................................................................................................................................................................................ 10

Contract Information ....................................................................................................................................................................................................... 10

Unit Information .............................................................................................................................................................................................................. 10

External System Resistance ............................................................................................................................................................................................ 10

Drives .............................................................................................................................................................................................................................. 10

Filters .............................................................................................................................................................................................................................. 10

Inlets and Discharges ..................................................................................................................................................................................................... 10

Separation / Mixing Boxes / VCDs .................................................................................................................................................................................. 10

Volume Control ............................................................................................................................................................................................................... 10

Heating / Cooling ............................................................................................................................................................................................................ 10

Plenums .......................................................................................................................................................................................................................... 10

Inlet / Discharges ............................................................................................................................................................................................................ 10

Vibration Isolators ........................................................................................................................................................................................................... 10

Flexibles .......................................................................................................................................................................................................................... 10

Attenuators ..................................................................................................................................................................................................................... 10

Ancillaries ........................................................................................................................................................................................................................ 11

Construction ................................................................................................................................................................................................................... 11

Finish .............................................................................................................................................................................................................................. 11

Protection ........................................................................................................................................................................................................................ 11

Site Costs........................................................................................................................................................................................................................ 11

Problems......................................................................................................................................................................................................................... 11

Delivery ................................................................................................................................................................................................................................ 12

Receipt & Unpacking ...................................................................................................................................................................................................... 13

Lifting .............................................................................................................................................................................................................................. 14

Crane - Long lifting straps - 150mm min. width ......................................................................................................................................................... 14

Crane – “H Frame” Short lifting straps - 150mm min. width ...................................................................................................................................... 14

Fork lift ....................................................................................................................................................................................................................... 15

Moving ............................................................................................................................................................................................................................ 15

Rollers ........................................................................................................................................................................................................................ 15

Skates ........................................................................................................................................................................................................................ 15

Toe Jacks .................................................................................................................................................................................................................. 16

Installation ............................................................................................................................................................................................................................ 17

General ........................................................................................................................................................................................................................... 18

Bases and foundations ................................................................................................................................................................................................... 18

Plug Fans ........................................................................................................................................................................................................................ 20

Fitting the Accessories .............................................................................................................................................................................................. 20

Electrical Connections ............................................................................................................................................................................................... 20

Rotary Exchanger Aluminium .......................................................................................................................................................................................... 21

Transport ................................................................................................................................................................................................................... 21

Mechanical installation .............................................................................................................................................................................................. 22

Hydraulic Connection ................................................................................................................................................................................................ 23

Installation of sensors ................................................................................................................................................................................................ 23

Electrical installation .................................................................................................................................................................................................. 23

Assembly of segmented rotary heat exchangers ...................................................................................................................................................... 23

IOM



Table of Contents 2

Storage ...................................................................................................................................................................................................................... 23

Commissioning .................................................................................................................................................................................................................... 24

SISW / DIDW Fans - Motors – Drives .............................................................................................................................................................................. 25

Belt Drives .................................................................................................................................................................................................................. 25

Anti-Vibration Mountings ............................................................................................................................................................................................ 27

Checking Label Positioning ............................................................................................................................................................................................ 27

Servicing Filters ............................................................................................................................................................................................................... 28

Mixing Boxes - Separation Boxes - Shut off VCD’s - HRD’s ........................................................................................................................................... 30

Coils ................................................................................................................................................................................................................................ 30

Coil Connections ....................................................................................................................................................................................................... 31

Setting Water Flow through Coils .............................................................................................................................................................................. 31

Coil Condensate Drains ............................................................................................................................................................................................. 32

Draw Through Units and Blow Through Units with negative pressure (depression at trap) .................................................................................. 32

Blow through units with positive pressure at trap .................................................................................................................................................. 33

Coil Condensate Faults ............................................................................................................................................................................................. 34

Draw Through ........................................................................................................................................................................................................ 34

Blow Through ........................................................................................................................................................................................................ 35

Draw through coils with condensate pump ........................................................................................................................................................... 36

DX Cooling Coils........................................................................................................................................................................................................ 37

Chilled Water Cooling and LP Hot Water Heating Coils ............................................................................................................................................ 38

Guidelines for water circuits in C.W. Coolers and LPHW Heaters ......................................................................................................................... 38

Bypass Circuit .................................................................................................................................................................................................. 38

Mixing circuit using three-way mixing valves. ................................................................................................................................................... 38

Chilled Water Cooling Coils ................................................................................................................................................................................... 39

Hot Water Heating Coils ........................................................................................................................................................................................ 40

Steam Coils ............................................................................................................................................................................................................... 41

Electric Heater Batteries ................................................................................................................................................................................................. 43

Gas Fired Heaters ........................................................................................................................................................................................................... 44

Electronic Steam Humidifiers .......................................................................................................................................................................................... 45

Rotary Exchanger ........................................................................................................................................................................................................... 46

Maintenance ........................................................................................................................................................................................................................ 47

Maintenance Schedule ................................................................................................................................................................................................... 48

Maintenance Action (not already indicated in Schedule) ................................................................................................................................................ 50

Plug Fans - Replacing the Motor and the Impeller .................................................................................................................................................... 50

SISW / DIDW - Fan Bearings ..................................................................................................................................................................................... 54

Spider Arm Bearing ............................................................................................................................................................................................... 54

Plummer Block Bearing ......................................................................................................................................................................................... 55

Direct Drive Fans ................................................................................................................................................................................................... 56

Replacing the filters (for HTM specification units) ..................................................................................................................................................... 56

Motor Bearings .......................................................................................................................................................................................................... 58

Motors without Grease Points .................................................................................................................................................................................... 58

Motor Overheating ..................................................................................................................................................................................................... 59

Washable Filters ........................................................................................................................................................................................................ 59

Autoroll Filters ............................................................................................................................................................................................................ 59

Activated Carbon (Constantly Monitored).................................................................................................................................................................. 59

Activated Carbon (disposable non-monitored).......................................................................................................................................................... 59

Electric Heater Batteries ............................................................................................................................................................................................ 59

Dampers - Motors ...................................................................................................................................................................................................... 59

Coils - General ........................................................................................................................................................................................................... 59

DX Cooling Coils........................................................................................................................................................................................................ 59

Rotary Exchangers .................................................................................................................................................................................................... 60

Fault Finding ........................................................................................................................................................................................................................ 61

Centrifugal Fans.............................................................................................................................................................................................................. 62

Electric Heaters ............................................................................................................................................................................................................... 63

Cooling Coils .................................................................................................................................................................................................................. 63

Heating Coils .................................................................................................................................................................................................................. 65

IOM



Purpose 3

Refrigeration ................................................................................................................................................................................................................... 65

Fan Drive Belts ................................................................................................................................................................................................................ 66

Purpose

This manual contains advice for installers and users.

General information about the range, construction and selection of ECE air handling/conditioning equipment can be

obtained from our website, various sales publications, or by telephone.

Certified individual unit data concerning dimensions, weights, component specification and performance, is issued with

the order acknowledgement for each unit.

Due to our policy of continuous improvement the information contained within this Manual may be altered from time to

time without prior notice.

IOM



Checks at Design Stage 4

Checks at Design Stage

IOM




Air Inlets and Discharges

Whether ducted, or part of the Air Handling Unit, inlet and discharge connections to atmosphere such as Louvres, Cowls,

Spigots, etc. should be located and dimensioned so that the flow restriction, short circulating, recirculation of vitiated air,

pick up of contaminated air or nuisance discharge of exhaust air do not occur.

Ducted intakes and discharges to units should be designed and constructed to ensure that flow restriction, turbulence,

pre rotation, jetting, uneven velocity profile and surface or object excitation do not occur.

Poor intake design causes uneven velocity profile across unit components resulting in moisture carryover hence flooding,

design supply air conditions not being achieved, electric heater elements overheating, DX refrigerant cooling coils

freezing and secondary generation of noise and vibration etc.

A.S. SCTV = Aerofoil Section Short Cord Turning Vane 50mm ctrs.

LCTV = Long Cord Turning Vanes to HEVAC – CIBSE – ASHRAE Standards

IOM




Poor discharge design causes reduction in fan pressure and volume, also turbulence generating secondary noise and

vibration, which may reduce impeller, bearing, isolator and flexible connection life. Design supply conditions may also be

achieved. Electric elements may overheat. DX coils may freeze.

A.S. SCTV = Aerofoil Section Short Cord Turning Vane 50mm ctrs.

D = Fan inlet eye diameter

LCTV = Long Cord Turning Vanes to HEVAC – CIBSE – ASHRAE Standards

IOM




Acoustics - Vibration

Ensure space exists for incorporating attenuation of the noise to atmosphere from outside air inlet and exhaust air

discharge and on room side supply and extract ducts.

Consider noise from casing radiation, flanking and breakout.

Consider primary and secondary vibration isolation including service connections.

Services - Connections

Ensure space with clearance exists for access to, routing of, connection to and expansion and contraction of water,

steam, refrigerant, gas oil supplies and line fittings. Combustion air supply, flue gas exhaust. Venting of air, isolating and

draining of plant, trapping and returning steam, condensate, trapping and draining of condense from cooling coils,

humidifiers and heat recovery devices to open tundish, blowing down waste to open tundish, pumping down and storing

of refrigerant, power – control wiring, and components.

Commissioning & Fault Finding

Ensure plant is designed to allow installation of and access to calibration and adjustment of measuring and modulating

devices for:

Air flow direction and rate

Medium flow direction and rate

Resistance to airflow

Resistance to medium flow

Air on and off dry bulb, wet bulb and humidity

Medium on and off pressure and temperature

Ensure space exists in and around the plant for access to, inspection of, measuring of and work on items including:

Belt tensioning of external motors

Jacking and levelling of steel spring vibration isolators

Clear sight of identifying labels measuring and recording devices

VCD blades, links and actuators, humidifier generators, sparge pipes, coil and eliminator surfaces and drain

pans, electric heaters, fan and drives

Fan speed and direction of rotation

Motor current, resistance, continuity

Motor nameplate

Terminal wiring diagrams

Wiring

IOM




Maintenance Repair and Renewal

For units with one piece coils ensure space exists of at least one unit width plus 150mm on the withdrawal side of each

plant item. For units with split coils ensure at least half the width of the unit or 700mm whichever is greater.

Adjacent units can share the common space between them for access and withdrawal.

Ensure room exists for safe working platforms where units are mounted at high level.

Ensure provision exists for steps, ladders etc. Where units are over 1750mm high or mounted on platforms which elevate

the unit height and make access difficult.

General

Any or all of the following and their effect on the plant should be considered and the appropriate action taken:

Conditions within surrounding areas

External temperature and humidity

Direct solar radiation

Wind speed and direction

Driven rain

Driven snow

Driven sand

Sea spray, mist, fog, moisture in suspension

Saline atmosphere

Icing

Unit surface temperatures and surrounding air dew point

Gases which form acids in solution in water, such as SO²

Flammability

Explosion risk

Toxicity

Bacteria

Fungi

Algae

IOM



Checks at Order Stage 9

Checks at Order Stage

IOM




General Information

Date

Time

Contact(s)

Company

Address

Phone Number

Fax Number

Email Address

Contract Information

Customer Ref. No.

Confidential? Job Name

Delivery Area

Specification Pages

Other Standards Referred To In Spec

Drawing No’s.

Schedule Reference

Other Customer Documents

Unit Information

Item No

Area Ref

Supply / Extract

Int / Ext / Roof / Fitted Works or Site

Part / Horiz

Part / Vert

Configuration / Sketch

25mm - 50mm Panels

External System Resistance

Depression at Unit Inlet

Positive at Fan Discharge

Pressurised Sep / Mix

Box / Plenum

Diffusion / Blanking Screen?

One-Two-Duplex-Triplex

DIDW - SISW

FC / BC

BD / DD

Raft / Rigid

I.G.V. + Controller

NRD’s One. Two.

Guards:

Inlet / Eyes / Disch / Drive

Drives

Motors Int / Ext

Duty / Idling

Pulleys / Belts / In / Out / Air Stream

1 Speed / 2 Speed / Variable Speed

Spd Change Interlock with EAHB.

Pole Change/Dual Wound.

Electromagnetic Clutch (TASC)

Switched Reluctance

Inverter

DOL / SD

St’ D/Flf

Elec Supply

Floor Grid

Lifting Beams

Filters

Presti.Stii

St.I. 11.111.

To Extract Heat Recovery

Grease to Kitchen Extract

Type

Efficiency by Weight

Efficiency Spot Dust

Retentivity (Act. Carbon)

BS. ASHRAE. Eurovent

Withdrawal - Side / US / DS / T / B

Fitted Manometer(s)

Magnehelic(s)

Radiant Heat from EAHB

Inlets and Discharges

Louvres / FAI / DTA / Std / Acoustic

Elmtrs + Drain High Velocity

Fan Discharge 45º Spigot + Mesh

Separation / Mixing Boxes /

VCDs

Int / Ext Dampers

FAI / RC / DTA Position

Opp / Par / Man / Motor Belimo

Volume Control

100% / Zone / F&BP / Location

Int / Ext.

Opp / Par / Man / Motor

Construction GSS

Heating / Cooling

Heat Recovery

Heat Rejection

Dehumidifying

Humidifying

Positon / Type

Draw Through / Blow Through

Volume M3/s

Air On Cwb / Deb / Kg / Kg

Air Off Cwb / Db / Kg / Kg

Sweating Ins Frame

Dx +Const Off = Freeze

Humid Posn Adj Surfaces - Wetting

Clear Distance Downstream

Gas Heater. Condensation - Bypass

Combst’n Air Inlet - Flue Output. Posn

Load / Eff / Output

Steps / Interplaced / Face

Medium Type

Flow Return ºc

Evap. Temp. ºc

Pressure – Bar / Kpa

Glycol %

Outside Ambient

Cond. Temp. C

Elec Supply

EAHB Min Air Flow Speed

EAHB Balanced Across 3ph Supply

Interlock With Var.Sp.Fan.

Construction

Plates / Tubes / Fins

Elements / Burner / Infill

Finish: Self / Vinyl / Et.

Free Cooling & Mechanical Top Up.

Air Entering At 90º to Coil Face.

Face Velocity Profile

Condensate Drain Provision - Height

Plenums

Location / Function

Diffuser / Spacer / Access

90º / Horz / Vert

To / From: Above / Below / LHS / RHS

Hinged / Lift Off.

Tool Op / Handles / Lock To One Handle

Viewport(s)

Bulkhead Light(s) Ext Switch

Wiring by Others

Floor Grids

Inlet / Discharges

From: Above / Below / LHS / RHS / Face

Louvre / Spigot

Stack & Cowl

90º + Sctv

Grill / SD / DD / NV / OBDs

Construction

Finish

Vibration Isolators

Int / Ext

Eff Required %

Rubber in Shear / Steel Spring

Jacking

Self-Levelling

Fixed/Loose

Flexibles

Isolating / Fan Raft / Fan Section

Compute Unit / Pipe Connections

Attenuating

Flame Resistant

Construction

Finish

Breakout

Flanking

Attenuators

Extract / Atmos / Room Side / Zone

Supply / Atmos / Room Side / Zone

To Achieve NR In / At

Unit/Duct Mounted

Straight /90 + SCTV

Volume m3/s

Inlet / Outlet Plenum / Length

From / To / Above / Below / LHS / RHS /

Face

Finish

Breakout

Flanking

IOM




Ancillaries

50 x 100 x 50 Full Perimeter Base

6mm Anodised Aluminium

3mm GSS

Integral Lugs

Support Legs

Support Steelwork

Side / Central Services Corridors

Pipework

Controls

Wiring

Access Platforms

Construction

Frame / GSS / Ali / Plastisol

Outer Panels / GSS / Plastisol

Inner Skin / GSS / Plastisol St. St.

Insulation 20mm / 50mm / 65kg / m3

Finish

Location Ext / Int

Anodised All

Plastisol

GSS Self

Protection

Polystyrene Corners

Cling Film Wrap

Polystyrene Boards

Rewrapped after Assembly

Site Costs

Site Supervision Work Required

Site Assembly Required

Safety Checks I.E. Gas Heaters

Guarantee Checks

I.E. Assembly Standards, Weathering and

Site Air Leakage Standards

Problems

Transport: Loaded Vehicle Obstacle

Clearance / Route Load Bearing

Road Closure / Stat Permissions

Onloading / Off Loading

Crane, Fork Lift Weight / Capacity

Moving On Site: Route / Loads / Method

Building Load Bearing

Max Size / Weight per Piece for Access

Dry Storage before Erection

Bases: Level / Load Brg / Relevelling

Dev’s

Bolting Adjacent Sections Onsite

I.E. Heating & Cooling Coils

Access / Maintenance / Withdrawal Plant

Sun / Wind / Rain / Snow

Saline / Icing

Dust / Powder / Grit / Soot / Smoke / Sand

Tall Units on Plinths Side Walkway?

Are Top Access Door Catches In Reach?

Containment & Drainage of Leaks

Sloping, Differential Trapped

Condense Drains, To Open Tundish

Miswiring Motors Competent Electrician

IOM



Delivery 12

Delivery

IOM



Delivery 13

Receipt & Unpacking

Units are designed and manufactured according to ISO 9001

As part of our quality control system each unit undergoes a full pre-delivery inspection before loading.

Units are then fitted with corner protection and wrapped in polythene to prevent ingress of foreign bodies or water during

transportation.

All units are fitted with a full perimeter bases to facilitate lifting, moving and installation.

Unit wrapped ready for dispatch

Units should be inspected and any external damage or short delivery reported to ECE, before unloading.

We cannot accept responsibility for damage sustained during unloading from the delivery vehicle or on site.

Units must be off loaded, lifted and lowered using long lifting straps and timber blocks or using an “H” Frame with short

lifting straps and timber blocks or a fork lift with extended forks.

Final lowering and side shifting to bring parallel faces together should be by toe jacks with timber blocks.

Internal joining bolts should never to be used to pull modules together.

Modules should never be rolled over to more across site.

Guidance notes for unloading and handling are given in the following pages.

Before commissioning all packaging materials must be removed from the units and cleared from the area.

IOM



Delivery 14

Lifting

Crane - Long lifting straps - 150mm min. width

Crane – “H Frame” Short lifting straps - 150mm min. width

IOM



Delivery 15

Fork lift

Moving

Rollers

Skates

IOM



Delivery 16

Toe Jacks

IOM



Installation 17

Installation

IOM



Installation 18

General

Electrical wiring and controls, water, steam, gas and refrigerant piping, line fittings and controls should be installed in

accordance with appropriate governing institute standard practice (I.E.E. C.I.B.S.E. etc) and together with the electricity

supply, water supply and drains should conform to the appropriate authority and all statutory regulations.

Units with drains should be mounted at a level which allows installation of cleanable drain taps at each connecting point

then installation of drain pipe work falling to an open tundish.

Space should exist for the application of sealant - jointing rubbers. Tightening of internal fixings. Internal installation,

attachment or insertion of isolating, indicating, recoding, modulating, activating, devices, also making and tightening of

fixings at connections to air Inlet and discharge ducts.

Bases and foundations

All units must be installed on a permanent base which must be firm, level and structurally rigid. Units may be mounted on

suitable steels or purpose build C.I. frames supported from the main roof structure providing this is capable of supporting

the weight - see Checks at Design Stage.

“The use of Tico material to dampen vibration / noise is not recommended as it will cause uneven

deflection due to variations in point loading within units. This will cause vertical joints to go “out of

parallel” causing leakage at joints”

IOM



Installation 19

When foundations are uneven units will “lozenge” if the installer attempts to use the joining bolts to pull non parallel faces

together causing air leakage at joins, access doors will jam and not close after opening and duct connections will not be

“parallel” and will leak.

Elevation Plan

When foundations are level and perfectly flat units will be perfect cubes and will fit together squarely with good air seals,

access doors will open and close correctly and duct connection are airtight.

Do not use joining bolts to pull units together in elevation or in plan.

Level Base – units perfect cubes

IOM



Installation 20

Plug Fans

The fan is secured to a base by bolts in mounting holes across anti-vibration mountings. The base must be level and

stable. The fan must only be mounted in a horizontal plane. Either the fan or the base is mounted on anti-vibration

mountings.

Fitting the Accessories

The fan should normally be connected to the air handling unit by means of flexible connection or other type of gasket to

eliminate vibration transfer from fan to AHU casing. Providing necessary grounding for the accessories is within the

constructor’s field of responsibility. Inlet protective screen can be fitted directly to the front frame or outside AHU to the

inlet opening.

Electrical Connections

All electrical connections must be wired by authorised personnel only. The necessary electrical and safety precautions

must be taken into account. If the motor is operated across a frequency converter, the connections must be made

according to the instructions of the frequency converter manufacturer. The motor must be grounded.

IOM



Installation 21

Rotary Exchanger Aluminium

The following checks must be performed before installation:

Has the rotary heat exchanger been damaged during transport (visual inspection of casing and wheel)?

Has the correct model been supplied (type, series, size, options)?

How must the exchanger be mounted (purge sector)? (Note labels!)

Transport

The wheel should always be vertical during transport

The rotary heat exchanger should be attached to the crossbars of the casing. The pulling direction should be

vertical to prevent damage

The following general items are applicable: Do not lift the exchanger at a single point but always suspend it by a

crane beam

IOM



Installation 22

Mechanical installation

The casing for duct connection can be bolted or riveted at the face area up to 4 cm from the outer frame

“The wheel casing cannot take any additional load (e.g. ducts)”

When installing the wheel in a ventilation unit, the casing should be reasonably adapted to the unit size

If necessary, baffle plates can be installed to adapt the casing to the unit cross-section

“Ensure that the wheel is not drilled or blocked and the sealings are not damaged during installation”

After installation check that the wheel runs smoothly.

IOM



Installation 23

Hydraulic Connection

If condensate is expected, ensure that it can drain away freely. Condensate drip trays are recommended on both sides,

i.e. for both air streams. Appropriately sized drains should be installed.

Installation of sensors

If, for example, temperature sensors are installed, the function of the unit must not be affected.

Electrical installation

Constant drive

The drive motor is electrically connected at the factory (in Y-circuit). The motor must be correctly fused. The direction of

rotation can be reversed by exchanging the phases.

Variable-speed drive

The control unit is supplied with the unit. The motor must be wired to the control unit and the control unit must be

connected during installation.

Assembly of segmented rotary heat exchangers

The installation manual for segmented wheels can be downloaded from the internet. To ensure correct function the

installation supervision by a manufacturer technician or an authorised supplier is recommended.

Storage

Rotary heat exchangers with motors must be stored in a dry, dust-free area which is free of vibrations

Long periods of standstill can impair the function of gear motors because after some time the bearings lose their

lubrication and the seals may become leaky. Too long storage periods must therefore be avoided

“If a rotary heat exchanger is not installed and commissioned within 9 months from the date of

delivery it must be put into operation for minimum 5 minutes in order to ensure the reliable operation

of the motor”

IOM



Commissioning 24

Commissioning

IOM



Commissioning 25

SISW / DIDW Fans - Motors – Drives

Access is by hinged or lift off panels. Catches are hidden quarter turn cams, tool or key operated.

Wiring to the motor(s) should be carried in flexible armoured conduit through screwed gland(s) fitted in holes(s) drilled by

the installer/user. NEVER THROUGH ACCESS DOORS.

Motors may be 240/1/50 or 415/50 TEFC, flameproof, super silent, single speed, dual speed, regulative or non-regulative

D.O.L. or Star Delta. DO NOT attempt to wire the motor without reference to the correct wiring diagram issued with the

unit.

Starters MUST have thermal overload cut outs and single phasing prevention devices.

Belt Drives

Slacken belt tensioner, remove belts, check impeller rotates freely and fan scroll is free of obstructions.

Remove locking bolts and shipping braces, if fitted, to protect vibration isolators during transport.

Adjust jacking self-levelling steel spring vibration isolators as instructions until floating and damped.

Check rubber in shear anti-vibration mounts for condition, tightness and free operation – bounce.

Inspect all bolts on motor, fan and frame for tightness.

Test run motor for condition and correct rotation.

Replace belts and check pulleys are correctly aligned as illustrated.

Adjust the belt tension according to the table

The lowest belt tension at which slip does not occur under load gives longest belt and bearing life.

Belt Section SPZ SPZ SPA SPA SPB SPB SPC SPC

Small pulley diameter Min 67 100 100 140 160 236 224 375

Max 95 140 132 200 224 315 355 560

KG force for 16mm* defl’n / metre span Min 1.0 1.5 2.0 2.8 3.5 5.1 6.1 9.2

Max 1.5 2.0 2.7 3.5 5.1 6.6 9.2 12.2

IOM



Commissioning 26

With all access panels in place, components installed and the cutting system complete, connected and commissioned,

check that measured full load current is less than motor nameplate full load current. Check that starter overload setting is

correct and that single phasing protection is functioning. If any problems occur refer to Fault Finding Section of this

manual.

The complete ductwork system should be proportioned to CIBSE - ASHRAE recommended procedure.

The Volume should be measured and if outside CIBSE recommendations or specified tolerances then;

Installer / commissioning engineer should submit full commissioning data to ECE.

ECE will calculate new fan speed required to achieve design volume and recommend pulley(s) & belt(s) sizes required to

achieve new fan speed.

Installer/commissioning engineer should then:

Purchase new pulleys and belts available locally from nationwide stockists

Change pulley(s) and belt(s) on site

Re-measure volume

Recheck proportion and volumes to air terminal devices

ECE site operatives are available for changing belts and pulleys on site at extra cost if required.

“Rotating standby motors generate electricity even when isolated from the mains. If the motor is

being rotated by the fan do not touch the terminals even if the motor is isolated”

The most common cause of incorrect fan volume is over estimation of system resistance. Please check this before

contacting ECE.

Unless specified otherwise fans are belted to give specified volume with clean filters.

Where the specification calls for design volume with dirty filters we recommend the incorporation of pressure activated

constant volume control since selection of the fan(s) at final system resistance could result in considerable excess

volume initially.

Excess volume can cause:

Coil off temperature, hence room supply air temperature, hence room temperature not being achieved

Water carryover and flooding

Motor overload and burnout

Increased fan noise levels

Turbulence and excitation of duct walls resulting in noise and vibration problems

Noise regeneration at changes of direction, volume control dampers and air terminal devices

Reduced filter life

Gross under volume can cause coil sweating, freezing and motor burn out.

IOM



Commissioning 27

Anti-Vibration Mountings

Checking Label Positioning

The positions of the Danger & Caution labels, these labels will always be positioned on the fan section doors.

Should for any reason these labels not be in position they can be obtained from ECE

The positions of the Caution Hot Surface labels, these are positioned on electric heater batteries and gas burners

where the surface on the outside of the AHU will be HOT.

Should for any reason these labels not be in position they can be obtained from ECE

IOM



Commissioning 28

Servicing Filters

Units are supplied with required filter fitted. After installation of the plant “Blow Through” ensure the system filters are

replaced by the installer at commissioning as follows.

Filter Ratings – use this chart to ensure you have the correct type

**If avoidance of pattern staining on surfaces is a priority use this standard or above

IOM



Commissioning 29

Type Retentivity

ka gas / kg carbon

Constant P.d.

N/m2ins. W.G.

Activated Carbon 0.1 – 0.4 112 0.45

Remove open side access doors (unless special access).

Thoroughly clean system.

Install temporary filters (gauze bags etc) on inlet discharge points.

Replace and close access doors.

Blow out system.

Remove contaminated temporary filters.

Replace filters, check sealing for bypass.

Replace doors.

Panel filters - Check airflow direction arrows.

Absolutes - Ensure pre-filters fitted, check sealing.

Autorolls - Check airflow. Autorolls have two end headers, one contained the clean spool, one the dirty spool

which is driven by a geared motor and chain drive, activated by a pressure differential switch with 10 seconds

delay. Usually a hand inching switch, a media available light and an end of roll indicator are fitted. The 2201/50

or 415/3/50 motor has starting currents between 1/3 and 7 amps and full load current between 0.3 and 1.5 amps.

Motor overload protection should be installed if not already fitted.

Maximum operating conditions Continuous Short period

Glassfibre panels 110oC 80% RH 110

oC 80% RH

Soft fibre panels 49oC 80% RH 49

oC 80% RH

Autroroll glassfibre 70oC 80% RH 70

oC 80% RH

Bag standard 100oC 80% RH 100

oC 89% RH

Bag extra fine superfine 100oC 100% RH 100

oC 100% RH

Fire resistant panel (BS.2963) 250oC 500

oC

Absolute corrosion resistant 66oC 100% RH 120

oC

Absolute medium temperature & humidity 70oC 80% RH 120

oC

Absolute fire resistant & self-extinguishing 250oC 100% RH 500

oC

Always replace media with IDENTICAL media.

Install anti-frost control on Autorolls to avoid media roll-on.

Install fan run-on control with high temperature heating mediums such as steam or electricity.

Pressure switches across filters only indicate blocked filters NOT low airflow due to other reasons e.g. blocked inlets

dropped fire dampers.

Install bag or absolute filters after the fan (with discharge plenum) to guarantee efficiency. Pre filters are still necessary to

protect the coils. Activated carbon filters must have coarse and fine pre-filters.

IOM



Commissioning 30

Mixing Boxes - Separation Boxes - Shut off VCD’s - HRD’s

Hand operated with locking quadrant

Check:

Free action of the damper blades and arm before setting at the required angle.

Motorised (motor not normally ECE)

Remove links and check:

Motor bolts and platform tight.

Electrical supply and connections correct.

Motor operates freely and in correct direction.

Dampers move freely.

Reconnect link(s) and adjust for required damper movement and check

Links are not adjusted so that motor attempts to push dampers BEYOND fully open or fully closed position in as

this can damage motor linkages and bearings.

Coils

General checks:

Coils installed in correct order for psychometrics.

Fin conditions, comb out if necessary.

Water coil checks:

Air and water are in counter flow.

Flow pipe work with drain cock fitted is to lowest connection.

Return pipe work with vent is from highest connection.

Drains at the lowest point, vents at highest point.

Frost protection exists for low ambient airflow or shut down conditions.

IOM



Commissioning 31

Coil Connections

Ensure connections to coils are bottom inlet and top outlet, this arrangement ensures thermal siphoning aids flow.

Performance will be limited it these connections are made the wrong way.

Refer to following section for full details on coil and condensate drain connections

Setting Water Flow through Coils

Open all manual valves fully – including the bypass valve on the three port control valves diverting port.

Ensure that the three port control is set to pass 100% flow through the air handling unit coil.

With the aid of a screwdriver open the two small inbuilt valves either side of the flow indicator window on the main

commissioning unit. The main commissioning unit is sited in the main return pipe (these small valves allow water to pass

through the indicator window to enable flow rate to be observed.

Set the flow rate through the coil by rotating the larger valve on the main commissioning unit to restrict the water flow until

the desired flow rate is indicated in the window. Once this valve has been set DO NOT adjust it again.

Move the three port control valve into the 100% bypass position.

Slowly close the secondary commissioning valve (sited on the three port control valves bypass port) at the same time

observe the flow rate being indicated in the window of the main commissioning valve. Continue closing this valve until the

same flow rate reading as before is obtained.

Conclude by closing the two small integral valves wither side of the indicator window on the main commissioning valve.

The system is now balanced.

IOM



Commissioning 32

Coil Condensate Drains

Draw Through Units and Blow Through Units with negative pressure (depression at trap)

10pa difference in pressure = 1mm difference in water level

i.e. 190mm = 1900pa depression -- 235mm = 2350pa depression

IOM



Commissioning 33

Blow through units with positive pressure at trap

10pa difference in pressure = 1mm difference in water level

i.e. 190mm = 1900pa depression -- 235mm = 2350pa depression

IOM



Commissioning 34

Coil Condensate Faults

Draw Through

Inadequate trap differential resulting in condensate drain tray overflow

and flooding

Not draining into an open tundish but connecting to a full pipe resulting

in condensate drain tray overflow and flooding

Trap not being primed with water resulting in condensate drain tray

overflow and flooding

Reverse pipe slope resulting in condensate drain tray overflow and

flooding

Blocked pipe connection(s)

Partial block = some flow resulting in condensate drain tray overflow

and flooding

IOM



Commissioning 35

Blow Through

Inadequate trap differential resulting in priming water blow-out “splutter”

and air leakage

Not draining into an open tundish but connecting to a full pipe resulting

in condensate drain tray overflow and flooding

Correct trap but not primed with water resulting in condensate blow-out

“splutter” and air leakage

Reverse pipe slope resulting in condensate drain tray overflow and

flooding

Partially of fully blocked pipe connection(s) resistance through blockage

greater than P resulting in drain tray overflow and flooding.

Partial block = some flow

IOM



Commissioning 36

Draw through coils with condensate pump

Pump sump primed with water

Fan off

Coil off

No difference in water levels

Fan starts and creates depression at

coil

Priming water in pipe rises 1 𝑥 𝐷Priming water in sump falls

1 𝑥 𝐷 𝑥 𝐴𝑟𝑒𝑎 𝑜𝑓 𝑝𝑖𝑝𝑒

𝐴𝑟𝑒𝑎 𝑜𝑓 𝑠𝑢𝑚𝑝Coil is still off so no condensate is

flowing

Fan still running and creating

depression at coil

Coil operating, condensate flowing

Water level in pipe rises

Water level in sump also rises until

HLFS operates

Pump starts

Pump runs

Water levels falls until LLFS breaks

Pump stops

H = depression at off face of cooling coil + difference in level between HLFS operating and pipe openings

10pa difference is pressure = 1mm difference in water level

i.e. 1900pa depression – 235mm = 2350pa depression

IOM



Commissioning 37

DX Cooling Coils

Coils are normally of open header box construction (but may have split end covers supplied to order) are completely self-

supporting and designed to be fitted directly between or within the sections of the air handling unit.

When split cover plates are supplied these should be removed prior to connections being made, then replaced. Great

care should be taken when tightening connections to avoid damage to the coil. The space between the pipe work and

cover plates should be sealed with a grommet or similar.

A correctly sized thermostatic expansion valve with external equalising connection must be fitted.

Run the liquid refrigerant line to the TEV which should be fitted to the liquid distributor, feeding the individual circuits of the

evaporator coil.

An adequately sized suction line should be run from the suction header to the compressor.

The valve equalising line should be run to the suction line on the compressor side of the valve sensitive phial which

should be placed on top of the suction line periphery and secured with a special clip.

A suction-liquid heat exchanger should be used to improve the performance of the expansion valve and utilise the

complete coil surface.

A correctly sized sloping drain line with cleanable “U” bend water trap terminating at an open drain or tundish should be

run from each drain connection.

A typical arrangement for direct expansion cooling coil (R22 Pipework Only)

IOM



Commissioning 38

Chilled Water Cooling and LP Hot Water Heating Coils

Guidelines for water circuits in C.W. Coolers and LPHW Heaters

Bypass Circuit

Tightly closing three-way valves are required as the regulating valves. At nominal flow the pressure drop across the

valves (pv100) should range from approximately the same value to about double the value of the pressure drop across

the heating load branch at nominal flow.

The balancing valves are used to adjust the water volumes for the individual heating circuits.

Mixing circuit using three-way mixing valves.

Slipper valves can generally be used. The nominal size is usually chosen equal to the nominal size of the pipe. However,

from the point of view of hydraulics, slipper valves one size smaller than the nominal size of the pipe are preferable.

In systems where the pressure difference between A and B exceeds approximately 0.8 mWG, it must be checked that the

leakage losses of the slipper valves remain within tolerable limits. If this is not the case, seat valves are to be used.

IOM



Commissioning 39

Chilled Water Cooling Coils






A correctly sized thermostatic expansion valve with external equalising connection must be fitted.

Run the liquid refrigerant line to the TEV which should be fitted to the liquid distributor, feeding the individual circuits of the

evaporator coil.

An adequately sized suction line should be run from the suction head to the compressor.

The valve equalising line should be run to the suction line on the compressor side of the valve sensitive phial which

should be placed on top of the suction line periphery and secured with a special slip.

A suction liquid heat exchanger should be used to improve the performance of the expansion valve and utilise the

complete coil surface.

If your unit is built to HTM standard each coil will come with a removable drain tray. A screw connection joins the tray to

the drain line, which can be detached so the tray can be removed and washed down.

A correctly sized sloping drain line with a cleanable “U” bend water trap terminating at an open drain or tundish should be


A typical piping arrangement for chilled water coil piped in counter-flow

A typical schematic for chilled water cooling coil

IOM



Commissioning 40

Hot Water Heating Coils






A correctly sized sloping drain line with a cleanable “U” bend water trap terminating at an open drain or tundish should be


Heater coil automatic control valves should be wired into the fan starter circuit so that valve motors close when fan is

stopped. This prevents temperature build up within the unit and possible harm to motor windings, particularly important

with high pressure hot water or steam coils.

A typical piping arrangement for hot water heating coil

A typical schematic for hot water heating coil

IOM



Commissioning 41

Steam Coils

Coils are normally of open header box construction (but may have split end covers supplied to order) are self-supporting

and designed to be fitted directly between or within the sections of the air handling unit.

When split cover plates are supplied these should be removed prior to connections being made, then replaced. The

space between the pipe work and cover plates should be sealed with a grommet or similar.

Check:

Supply is under 100 PSIG dry.

Supply is free of air and connected to the top coil connection.

Connecting pipe work is not supported by coil.

Expansion allowance made for coil tubes.

Connections are free from stress and are properly pitched and drained (to avoid water hammer).

Condensate connections to the steam trap are the same size as the coil outlet.

Condensate in the main is independently trapped on a coil bypass.

The steam trap is sized on 3 times the design flow.

Float or bucket type traps should be carefully selected to suit the steam pressures and temperatures with

thermostatic air relief traps on low pressure systems and continuous venting petcocks on medium and high

pressure systems.

Multiple or banks of coils must be individually trapped to meet the demands of the varying capacities and

pressures on each section.

Selection of control valves must be based on the steam load and not the size of the steam coil supply

connection.

Automatic steam control valves are suitable where the condensate is returned to atmospheric pressure or under

vacuum.

They are not recommended on systems where pressure is maintained on the return lines.

Steam pressure in the coil is not used for lifting condensate.

If coil is near filter ensure fan runs on after steam supply is cut off (2 minutes).

Note:

Over tightening connections damages coils.

Initial rapid heat build-up causes damage to coils and associated pipe work, valve opening must be gradual.

Check for leaks on initial start-up and after a short period of operation.

IOM



Commissioning 42

A typical piping arrangement for low pressure steam or vacuum system A typical piping arrangement for high pressure steam system

IOM



Commissioning 43

Electric Heater Batteries

“If not properly installed and controlled EAHB’s are dangerous. They can cause serious injury or

death and start fires. Ask your local electricity board fire officer and engineers department to inspect

your installation before use”

Access is by the access door clamped on the side of the unit. Cable entry should be made by drilling a suitable hole in

the folded angle corner posts. Screwed glands with cable holding devices should be used at all drilled holes. Do not

use P.V.C. cable inside the unit.

Generally elements are intended for phase to neutral connection balanced across 415/3/50 supply e.g. 3 elements phase

to neutral stage. Before connecting out of balance loads consult with your local electricity board.

All wiring must to be to I.E.E. regulations and conform to all local and national statutory requirements.

A high temperature S.P.D.T. cut out which opens at 165C is fitted, and must be wired in line with the coil of the main

EAHB contact breaker. Should this cut out operate, the cause must be ascertained before the hand reset is pushed back

in, since the elements may rise to 600Cin still air causing filter damage, motor burn out and fire damper link failure etc.

etc.

An airflow switch rated at the correct minimum velocity must be fitted (a filter pressure differential switch is NOT suitable).

Fan interlock with the EAHB and fan overrun (of up to 10 minutes after heater battery off depending on EAHB bank size)

must be fitted together with automatic recycle to zero load on step controller.

Always ISOLATE the supply before removal of access door and REPLACE the access door before reconnection of

supply.

The element tray must be earthed.

Typical schematic for electric heater battery

IOM



Commissioning 44

Gas Fired Heaters

Safety Notes:

Commissioning is recommended by our operatives, in any event gas piping, flue, electricity supply and controls

should comply with gas safety, gas region, local authority, fire authority and insurance company regulations.

Do not locate in presence of chlorinated or corrosive vapours, in areas of high risk i.e. cellulose spraying, near

combustible materials or where atmospheric depression i.e. an area with extract fan or system, could cause gas

reverse flow into area.

Ensure 24” minimum clearance all round this section.

Do not obstruct or modify build in diverter.

Except for servicing never switch off the power supply to the unit.

Internal Safety controls comprise:

Main gas valve closure if pilot light out

Fan on delay unit burner warm.

Gas off on overheat.

Fan off delay until burner cool.

External services required:

Natural gas supply

Combustion air supply

Combustion gas flue

Electricity supply for controls

Electricity supply for motive power

Flue gas discharge:

Flue gas leaving the top spigot at 260deg C should be vented to atmosphere using a gas board approved flue

terminal via a properly sized, individual, VERTICAL, natural draught flue rising 1.8m min.

Unavoidable horizontal runs (max 3m) should slope 65mm in 300mm and have final verticals riser of 1.5 times

the horizontal run. If these conditions cannot be met then factory installed fan assistance should be considered.

If condensation is possible it should be avoided by using double skinned flue with special joiner and spigot

(consult your local G.A.). If condensation still occurs a non-corrosive 22mm (min) drain should be fitted.

External controls required are:

On/off switching (time clock start/stop, thermostat controlling burner)

Normal electrical controls (fan motor starter, contactors and overload isolators etc.)

Wiring:

Refer to appropriate diagram supplied with unit and not the following:

Switching must be by individual 24V controls to each unit and should incorporate a 24V thermostat, switch and

time clock in series.

Never apply higher voltages (240V supply to motor of time clock must be separate).

Power into the control box can only be 220V l phase 50c/s.

Single phase fan motors up to 0.5kw (0.7 h.p.) can be connected via thermal overloads direct to the box.

Over 0.5kW single phase and all 3 phase motors must have separate electrical supplies controlled from the box

via a 240V contactor relay and should be protected by thermal overloads.

IOM



Commissioning 45

Inspection prior to initial start up

Gas shut off valve closed:-

Check all electrical functions - fan motors, room thermostat and gas control set/automatic gas safety system.

Check correct rotation of fans.

Gas shut off valve open:-

Carefully vent and check all gas lines for leakage by soapy water testing.

Close gas shut off valve.

Initial start up

Switch on main switch

Supply air discharge(s) open

Room thermostat “off” lowest setting

Time switch at “on” period

Turn on main gas

The unit will now start

Refer to user manual supplied with gas heater unit for details start up procedure.

Electronic Steam Humidifiers

Humidifiers supplied for use with ECE units are electrode boilers which operate at atmospheric pressure and utilise

standard water supplies provided the local regulations regarding connection of this type of equipment are observed. If

local regulations call for the use of a break tank to feed the unit, the speed at which the humidifier cylinder fills with be

determined by the head pressure available. The size of tank, its height and the size of its connecting pipe work must be

chosen carefully to ensure the unit always receives an adequate water supply.

A built in flow regulator compensates for pressure fluctuations.

Water - drain connections

Standard unit inlets are supplied with 15mm brass compression fittings.

Drains are brass couplings of l.5” BSP male thread and 1.25” BSP female thread sizes.

Power Supply

Connect using conduit entry glands through appropriate knockouts in casing.

Wiring should comply with the relevant local regulations using appropriately sized circuit breakers.

Control connection

When step control or modulation is required, the boiler, services and controls are mounted in a cabinet which

may be fixed to the side of the air conditioning unit or to an adjacent vertical surface BELOW the sparge pipe

level.

When on-off switching only is required the boiler and its services may be mounted inside the air conditioning unit

with the control panel remote.

Start up

Close electrical panel

Turn on water supply to humidifier

Close circuit breaker feeding power supply to humidifier

Put run/drain switch into the “RUN” position

Put on/off switch into the “ON” position

Humidifier will now operate to the demands of the control circuit.

IOM



Commissioning 46

Operation of typical electronic steam humidifier

Rotary Exchanger

Check the correct direction of rotation of the wheel - it is marked by arrows on the casing

Check the function of the control unit

Ensure that the air streams of the rotary heat exchanger can flow through without obstacles

Check that the installation is correct and whether application limits (temperatures, differential pressure, material,

etc.) could be exceeded

Check the tension of the drive belt and the fastening of the motor

Inspect the sealing on the wheel. When making adjustments, ensure that he wheel rotates smoothly and is not

blocked. The drive torque must not be exceeded

IOM



Maintenance 47

Maintenance

IOM



Maintenance 48

Maintenance Schedule

Item Interval (in months)

1 2 3 4 6 12

SISW / DIDW Fans:

Fan impeller cleaning

Fan motor – cooling vents clear, bearings check

Fan vee-belt drive, wear, tension, alignment

Plug Fans:

Check and lubricate the motor

Clean the impeller using a vacuum cleaner, compressed air or by brushing. Greasy dirt can

be washed with detergent or a solvent

Filters:

Filter panels check, clean or renew as necessary

Filter bag check, clean or renew as necessary:

Standard

Fine

Extra fine

Filter absolute and activated carbon check, clean or renew as necessary

Filter autoroll check, clean or renew as necessary

Filter condition indicator and autoroll controls – operation

Coils:

Coils venting

Coils surfaces, connecting piping

Electric Air Heater Battery:

EAHBs continuity, earthing, HT cut out

Wiring, flow switch, fan overrun, controls

Dampers:

Bearings, links, free movement

Motors, bearings, free movement

IOM



Maintenance 49

Gas Burners:

All points

Humidifiers:

Humidifier cylinder electrodes

Humidifier controls, wiring, piping

Rotary Exchangers:

Maintenance is restricted to regular visual inspections. Inspections should be initially carried out about every three months and then after trouble-free

operation can be extended to 12 months

Tension of drive belt

Sealing of gear motor

Quality of bearings (assess by bearing noise)

Function of slide seal

Function of transverse seal

Condition of casing

Condition of wheel

General Maintenance:

Metal, paint, sealing strips, sealant, fixings

Insulation, A/Vs, flex, connections, fixings

Wiring, controls, earth continuity

* indicates a one-off activity

This Schedule is not intended to be exclusive, inclusive or mandatory. Different conditions of use may dictate shorter or longer periods and or more

intensive action.

IOM



Maintenance 50

Maintenance Action (not already indicated in Schedule)

Plug Fans - Replacing the Motor and the Impeller

The fan will have to be disconnected from the unit before the motor can be replaced

1. Disconnect the electrical cables from the motor terminals

2. Dismantle the fan (including the anti-vibration mountings, if needed) from the unit

3. Dismantle the motor from the motor mount

4. Dismantle the front plate

IOM



Maintenance 51

5. Remove the impeller from the motor shaft by removing the clamp screw and top screw

IOM



Maintenance 52

6. Use an extraction tool to pull the impeller off the shaft (the motor can be moved backwards if needed, take care

so the motor does not drop down). Use the groove on the hub to pull the impeller. The bigger the impeller the

stronger the puller should be. The same applies in humid conditions

IOM



Maintenance 53

7. When using an extraction tool please follow the general instructions for the removal tool (correct work methods,

tighten and knock the head of the tool to check if it is tight, use of heat)

8. Mount a new motor on the motor bracket, do not tighten

9. Mount the fan impeller on the motor shaft (if necessary, clean shaft and hub inside)

10. Mount the front plate

11. Tighten the supporting bars

12. Mark the needed overlap in the inlet cone

13. Check the gap between the fan impeller and inlet cone

14. Align the fan impeller

15. Tighten the motor on the motor bracket and lock the impeller

“Check that the fan impeller does not touch the inlet cone”

IOM



Maintenance 54

SISW / DIDW - Fan Bearings

Spider Arm Bearing

Sealed ball races mounted in rubber, pre-greased and self-aligning for service free use under normal duties.

TL3 up to 400 and TL3 450-630 THLZ Duplex – 3 No. spider arm bearings

Units in the ECE range fitted with spider arm bearings

IOM



Maintenance 55

Plummer Block Bearing

Sealed ball races, mounted in cast iron supports, self-aligning and pre-greased with grease points.

Extended shaft ‘A’ frame NTH3 T1 and T2 710 – 1000

Units in the ECE range fitted with Pillow Block bearings

IOM



Maintenance 56

Direct Drive Fans

The impeller is keyed to the motor, which is mounted on a support attached to the fan casing. Motor bearings are sealed

ball races mounted in rubber, pre-greased and self-aligning for service free use under normal duties.

Replacing the filters (for HTM specification units)

All filters are fitted to universal filter frames. The filters are fixed using C70 clips. To replace a filter:

IOM



Maintenance 57

Unclip the fastening pins and pivot them in their base

Once all the clips are loosened the filter will start to come out from the top. Pull the filter out and check neoprene

tape for damage, replacing as required

Push the new filter into the frame, making sure the pleats are all vertical and the filter seals against the neoprene

tape

IOM



Maintenance 58

Re-fasten the C70 pins

Motor Bearings

Self-aligning self-oiling and spring loaded ball lubricators, use light machine oil.

Pressure grease fittings and relief plugs, wipe down fitting, remove pressure plug (if fitted) and hardened grease. Add

grease till NEW grease is expelled, run motor for 10 minutes, stop motor, clean and replace plus.

The bearing should be repacked with Shell Alvania 2, BP Energygrease 2 or Esso Beacon 2, leaving room for expansion

(These greases are suitable for temperatures between -30 C and + 110C).

If a rumble, knock or scrape is heard the motor should be replaced or examined and repaired by an electric motor repair

specialist.

NEVER subject the shaft to hard blows, as this may cause damage to the bearings resulting in noisy running and reduce

list.

Motors without Grease Points

Remove belts, run motor and apply the tip of a screwdriver to motor body (not shaft!) and the handle to your ear. A

purring sound should be heard. If a squeaking noise is heard the bearing is dry and should be cleaned and flushed, out

with a mixture of Tuoline and methylated alcohol (or, in an emergency, white spirit, never petroleum or paraffin).

IOM



Maintenance 59

Motor Overheating

Check for overheating, ascertain cause and rectify.

Washable Filters

Wash in mild detergent, rinse and squeeze dry.

Autoroll Filters

Check oil level in gearbox, lightly oil chain drive, lubricate drive motor, oil end of roll indicator arm.

Activated Carbon (Constantly Monitored)

When gas absorption drops below limiting level remove, replace with spare set and sent laden set for reactivation of

discard.

Activated Carbon (disposable non-monitored)

After 1 month usage remove test element or one cell (install new cell) and send for analysis and prediction of remaining

life. Replace filters completely within predicted period.

Electric Heater Batteries

Particularly check condition of wiring and insulation, plus surrounding paintwork/metalwork for signs of overheating.

Dampers - Motors

Lightly oil damper and motor bearings and link swivels – except nylon bearings.

Coils - General

Check finned surfaces every six months for build-up of dirt or lint. If required wash down with mild detergent solution and

soft brush and blow out any solids between fins with compressed air line. Take care not to disturb the fin surfaces or

probe the coils with metal scraper as damage may cause leaks.

At six monthly intervals ensure that the condensate drain lines are unobstructed and functioning.

DX Cooling Coils

During winter the refrigerant should be pumped over into the liquid receiver and the isolating valve shut. Enough gas

should be left in the system to keep a positive pressure in it. Before restarting, the plant should be checked for refrigerant

leaks.

IOM



Maintenance 60

Rotary Exchangers

Long experience shows that clogging of heat exchanges is not expected in normal cooling and air-conditioning systems.

However, if deposits accumulate on the exchanger when used for special applications, it can be cleaned as follows:

Remove dust and fibres with a soft brush or vacuum cleaner. Use caution when blowing dirt out with

compressed air to avoid damage to the wheel. Keep clear!

Oils, solvents, etc. can be removed with hot water (max 70oC) or grease-removing solvents or immersions

Cleaning with pressure cleaners is possible if the following is observed:

A flat 40o nozzle is used (type WEG40/04)

Max water pressure 100 bar

“Do not damage the exchanger mechanically or chemically during cleaning. Select compatible

cleansing agents and clean carefully. The thickness of the material is less and 0.1mm!”

IOM



Fault Finding 61

Fault Finding

“Check for broken wires or loose cable shoes first, also at control panel”

IOM



Fault Finding 62

Centrifugal Fans

Fault Check

NO AIR FLOW

Fan motor stationery

No current to motor

Motor connected

Wiring or isolator (on?)

Fuses intact

Wiring to starter (on?)

Starter wired properly

Overloads holding in and correct size

Wiring to time clock at “on phase”

Wiring to panel/mains (on?)

Other control circuits holding fan(s) off (eg. gas fired heater warm

up)

NO AIR FLOW

Fan motor running

Current to motor

Jammed impeller

Seized fan/motor bearings

Drive belts too tight

Motor windings/wiring faulty

Motor wrongly connected

Wrong voltage

NO AIR FLOW

Fan motor running

Fan stationery

Jammed impeller

Drive belts loose or missing

Impeller loose or missing

NO AIR FLOW

Fan running

Louvres blocked

VCD’s closed

Filters blocked

Cooling coil frozen solid

Duct blocked

Fire damper link failed

Grilles closed

LOW AIR FLOW Check as for no air flow plus:-

Fan rotation incorrect

Filters back to front

Media wrong

Drive belts slack or greasy

Pulley ratios wrong

Duct resistance exceeds design

Duct leaking on pressure side

Access doors off

Duct joint not sealed

HIGH AIR FLOW Low initial clean filter resistance

Filter missing

Duct incomplete or leaking

Pulley ratios wrong

Backward bladed impeller installed as

forward

System resistance over estimated

MOTOR CURRENT

EXCEEDS NAMEPLATE F.L.C.

Check as for no airflow, low air flow, high air flow

IOM



Fault Finding 63

Electric Heaters

Fault Check

NO HEAT All controls, protective devices and interlocks as described in

“Commissioning” section are installed

Thermostat setting too low

Time clock at “on” phase

Filters clean

Airflow adequate

Isolator connected

Mains switch on

Power from mains

All wiring connected

High temperature cut out button in

Continuity across H.T. cut out terminals

Airflow switch making and breaking

Voltage to airflow switch terminals

Contactor coil functioning properly

Fuses not blown

Step controller functioning properly

Fan - EAHB interlock functioning properly

If low airflow refer to “Low Airflow” centrifugal fan section.

If the high temperature cut out has operated

do not run system until reason for “cut out”

has been found.

LOW HEAT Wrong elements supplied

Element failure (open circuit or down to earth)

Elements disconnected

Elements incorrectly wired

Wrong voltage

Thermostat too low

Step controller sticking/faulty

Wiring fault

Other controller equipment fault

Cooling Coils

Fault Check

NO COOLING

Current to plant

Thermostat setting too high/faulty

Time clock at “on” phase

Motor not connected

Overloads tripped

(continue checks as for airflow in “fans”)

NO COOLING

HP cut out functioning

Correct setting

Faulty condenser

Heat rejection faulty

Fans and pumps stopped

Condenser blocked

LOW OR NO COOLING

LP cut out functioning

Suction pressure/evaporating temperature too low

Coil freezing up

Condenser too large for evaporator

Low air flow

Uneven air flow

Low entering air temperature

Humidistat(s) calling for dehumidification

Low compressor capacity control installed and functioning

IOM



Fault Finding 64

NO COOLING

Chilled water isolating valve closed

Thermostatic valves closed

Thermostat failure

Circulating pump failure

NO COOLING

LP cutout functioning

Expansion valve freezing

Water in system

LOW COOLING

Fridge plant cycles

Low load (unloader) compressor capacity control functioning

Step controller functioning

Other modulating controls functioning

HIGH RH Humidistat or dewpoint stat too high / faulty

No cooling

Coil fault (see above)

Entering air temperature too high

Insufficient cooling capacity (maybe start up, pull down time)

Excessive fresh air or airflow

Excessive moisture gain

Moisture carryover

LOW RH Stat too low / faulty

Coolant too cold

Refrigerant plant capacity too high

Inadequate controls

Insufficient air flow

COIL SWEATING Blocked filters

Blocked coil face

Air on dewpoint condition higher than design

Chilled water flow temperature or DX evaporating temperature

lower than design

MOISTURE CARRY OVER FROM FINS (or past eliminators if fitted) Check as for “coil sweating”

High volume

Uneven face velocity

Eliminators omitted in error

MOISTURE CARRY OVER FROM DRAIN TRAY (or drain tray not

emptying or leaking)

Horizontal

Undamaged

Drain tray outlet to U-trap not clocked

Primed adequate differential U-trap drain

Adequately sized correctly pitched condense line dropping into

open tundish

Upstream restricted airflow causing depression at coil greater than

U bend differential

Cover plates leaking air on bolt on coils

IOM



Fault Finding 65

Heating Coils

Fault Check

NO HEAT Thermostat too low/faulty

Time clock at “on” phase/faulty

Pump failure

Boiler plant off

Automatic valve closed due to thermostat

Valve transformer failure

Isolating valves closed

Airlock

LOW HEAT Check flow and return temperature - if low check boiler plant and

controls

Check flow rate – if low check:-

Regulating valves open

Insufficient pump head

Piping sizing wrong

Blockage in coil or high coil resistance (check temperature change

across coil and equal tube temperatures).

Warm up time adequate

Refrigeration

Fault Check

HEAD PRESSURE TOO HIGH Refrigerant overcharge - vent excess charge

Air in system - leak test, repair leak, evacuate and recharge

Dirty Condenser - clean

Malfunction of condenser fan (air cooled) - check head pressure

speed control if fitted

Restricted water flow - check flow rate and adjust

Water on temperature too high - cooling tower operation

Blockage in discharge pipe work - check and replace damaged

section(s) evacuate and recharge

High air temperature entering condenser (air cooled) spill over

between adjacent condenser, fit baffle or re-site condensers

LOW HEAD PRESSURE Refrigerant under charge - leak test, add refrigerant if necessary

Over condensing - Fan speed too high (air cooled), water flow too

high (water cooled)

Faulty valves

Low external ambient - pre heat air to cooled condenser

Low back pressure

HIGH BACK PRESSURE Air flow too high – adjust belt drive as necessary

Room temperature or air on too high – adjust thermostat

Faulty expansion valve

Also see– “Head pressure too high” above

LOW BACK PRESSURE Air flow too low – adjust belt drive as

Filters dirty

Shortage of refrigerant – leak test add refrigerant as necessary

Faulty valves

Blockage in pipe check and replace damaged section(s) evaluate

and recharge

SUCTION LINE SWEATING BACK TO COMPRESSOR Expansion valve open too wide

IOM



Fault Finding 66

Fan Drive Belts